Loose-fill cavity insulation by pneumatic injection

Abstract

A method is provided of installing flowable fibrous insulation in the cavity between the studs of a wall under construction, the wall cavity being open on one side and otherwise enclosed. The method includes covering the open side of the wall cavity with a removable pressure plate to substantially enclose the wall cavity. The pressure plate contains at least one aperture, preferably positioned proximate the top of the pressure plate. The wall cavity is substantially filled with flowable fibrous insulation delivered through the aperture in the pressure plate. The pressure plate is removed, and subsequently the wall cavity is enclosed by addition of the interior wall surface. A blowing wool-grade glass fiber insulation can be used. The method permits construction of well-insulated exterior walls sheathed with a material having an integral vapor barrier and having a wall cavity filled with densely-packed loose-fill insulation. The method permits insulating any partially open cavity.

What is claimed is: 
     
       1. A method of installing flowable insulation in a wall under construction, the wall having at least one volume defined on two sides by a pair of generally parallel studs, on the top by a top plate, on the bottom by a sole plate, and on the back by a generally planer surface, the front side of the volume being open, the method comprising: (a) first covering the open side of the volume with a removable substantially rigid, insulation support means to substantially enclose the volume, the insulation support means containing at least one aperture;   (b) then substantially filling the volume with flowable insulation materials with sufficient fiber length to be free-standing after filling and removal of the support means, with such insulation being delivered through the at least one aperture in the insulation support means;   (c) then removing the insulation support means, leaving the insulation in the volume freestanding and unsupported across the open front side; and   (d) subsequently enclosing the volume across the open front side.   
     
     
       2. A method according to claim 1 wherein the flowable insulation materials comprise fibrous material. 
     
     
       3. A method according to claim 1 wherein the flowable insulation materials are glass fiber insulation. 
     
     
       4. A method according to claim 3 wherein the glass fiber insulation is delivered to substantially fill the volume at a density of from about 2.0 to 2.5 lb/ft 3 . 
     
     
       5. A method according to claim 4 wherein the glass fiber insulation is a blowing wool-grade glass fiber insulation. 
     
     
       6. A method according to claim 1 additionally comprising covering the volume with a vapor barrier after the insulation support means is removed. 
     
     
       7. A method according to claim 6 wherein the vapor barrier comprises polyolefin sheet. 
     
     
       8. A method according to claim 1 wherein the insulation support means comprises a rigid, transparent member for viewing the flowable insulation as the flowable insulation is supplied to the volume through the at least one aperture. 
     
     
       9. A method according to claim 1 wherein the insulation support means comprises means for temporarily holding the insulation support means in position as the flowable insulaton is delivered to the volume. 
     
     
       10. A method according to claim 1 wherein the one side of the volume which is open is generally planar, and the insulation support means comprises a generally planar member. 
     
     
       11. A method according to claim 10 wherein the insulation support means additionally comprises sealing means for temporarily sealing the open side of the volume using the insulation support means. 
     
     
       12. A method according to claim 1 wherein the flowable insulation materials are pumped from a remote supply through a flexible conduit, the flexible conduit extending through the at least one aperture in the insulation support means. 
     
     
       13. A method according to claim 12 wherein the flexible conduit has an open end, the open end being positioned within the volume, the height of the open end being varied by an operator as the flowable insulation materials are delivered to the volume. 
     
     
       14. A method according to claim 1 wherein the at least one aperture is positioned proximate the top of the insulation support means. 
     
     
       15. A method of insulating an exterior wall of a structure under construction, the exterior wall having an interior volume having one open side and being otherwise enclosed, the method comprising: (a) first covering the open side of the volume with a removable, substantially rigid insulation support means to substantially enclose the volume on all sides thereof;   (b) then substantially filling the volume with flowable insulation materials with sufficient fiber length to be free-standing after filling and removal of the support means;   (c) then removing the insulation support means, leaving the insulation in the volume free-standing and unsupported across the open front side; and   (d) subsequently enclosing the volume across its open side.